Reinforced composite structural members and methods of making the same

ABSTRACT

There is disclosed a reinforced extruded composite structural member and a method of forming the same. The structural may member comprise a solidified composite mixture of a fibrous material and a resin, and a reinforcing member embedded therein. The reinforcing member may have a known tensile strength, and at least one physical characteristic adapted to promote bonding of the reinforcing member with the surrounding fibrous material.

This application claims the benefit of U.S. Provisional Application No.60/474,518 filed on May 30, 2003, the contents of which are incorporatedby reference herein in their entirety.

FIELD OF THE INVENTION

This invention relates to reinforced composite structural members andmethods of making the same.

BACKGROUND OF THE INVENTION

Structural members such as beams and joists made from compositematerials are known. The composite material may be made, for example,from a mixture of (1) a natural fiber and (2) a resin. The natural fibermay be wood fiber, or another type of natural fibrous material,available in various processed forms such as flakes, strands, particlesand chips. As used in this specification, the term “resin” refers to apolymer having an indefinite and high molecular weight, and acharacteristic softening or melting range, exhibiting a tendency to flowwhen heated and subjected to stress. A composite mixture of wood fibersand resins is often referred to as “composite wood”. Examples ofcomposite wood materials are described in U.S. Pat. No. 3,888,810 toShinomura, the contents of which are hereby incorporated by reference.

Structural members, such as joists, beams and sections of decking orwalkways, can be formed from composite wood materials by extrusion andpultrusion techniques. Examples of some techniques that can be employedare disclosed in U.S. Pat. No. 5,783,125 to Bastone et al., U.S. Pat.No. 5,096,406 to Brooks et al., U.S. Pat. No. 5,096,645 to Fink and U.S.Pat. No. 5,234,652 to Woodhams et al., the contents of all of which arehereby incorporated by reference.

There has, however, been a desire to improve the strength andperformance characteristics of composite structural members,particularly for structural members such as beams and joists asreferenced in U.S. Pat. No. 6,015,611 to Deaner et al., the contents ofwhich is also hereby incorporated by reference.

Certain techniques for strengthening and reinforcing extruded structuresare known, as described for example in U.S. Pat. No. 5,792,529 to May,and U.S. Pat. No. 3,993,726 to Moyer. However, the application of thesetechniques to composite materials made from natural fiber and resin maynot be straightforward. For example, in comparison to pure thermoplasticand synthetic materials, the viscosity of a composite wood mixture priorto extrusion may be relatively high due to the presence of naturalfibers, and therefore the composite wood mixture may not easily flowaround and bond to a reinforcing member. Also, a relativelyhigh-viscosity composite wood mixture may tend to misalign a flexiblereinforcing member, having a detrimental effect on the structuralproperties of the embedded reinforcing member.

Therefore, there is a need for an improved method of forming areinforced composite structural member, and in particular thosecomposite structural members including natural fibers such as woodfibers.

SUMMARY OF THE INVENTION

The present invention discloses a reinforced composite structural memberhaving a continuous reinforcing member embedded therein. In an aspect ofthe invention, there is provided a reinforced composite structuralmember, comprising:

-   -   a solidified composite mixture of a fibrous material and a        resin;    -   a reinforcing member embedded therein, said reinforcing member        having at least one physical characteristic for promoting        bonding of said reinforcing member with said mixture of a        fibrous material and a resin.

In an embodiment, the reinforced composite structural member may beformed by extrusion.

In an embodiment, the physical characteristic comprises an increasedbondable outer surface in comparison to a reinforcing member of asubstantially similar shape and size having a substantially smooth outersurface.

In an embodiment, the reinforcing member may comprise, for example, astrip. The strip may have a plurality of flow-through apertures providedalong its length. The flow-through apertures may be adapted to allow thecomposite material to flow therein and solidify, thereby providing anincreased bondable surface area and helping to secure the reinforcingmember within the extruded composite structural member.

In another embodiment, the reinforcing member may also comprise abraided cable or tow which provides a sufficiently coarse outer surfacefor facilitating secure bonding within the composite mixture. The coarseouter surface may provide an increased bondable surface area to securethe reinforcing member within the extruded composite structural member.

The reinforcing member may be delivered in a flexible format, allowing asufficiently long length of the reinforcing member to be supplied, forexample, on a supply reel in order to make a continuous extrusion runpossible.

The outer surface of the reinforcing member may be heated just as thereinforcing member is introduced into the extrusion apparatus. Bondingbetween the reinforcing member and the composite mixture preferablyoccurs immediately adjacent the extrusion apparatus outlet.

Suitably sized and shaped guide channels may be used to guide thereinforcing member and properly align the reinforcing member forembedding in the extruded composite structure.

The reinforcing member may be treated with a suitable resin that is thesame as, or compatible with, a suitable resin used in the compositemixture. Suitable resins may comprise, for example, low densitypolyethylene (LDPE), high density polyethylene (HDPE), polypropylene,PVC, or another polymeric material, such as those referred to in U.S.Pat. No. 5,783,125 to Bastone et al., the contents of which are alsohereby incorporated by reference, or in U.S. Pat. No. 6,015,611 referredto above.

Suitable resin bonding pairs for the reinforcing member and thecomposite mixture include, for example, LDPE and LDPE, HDPE and HDPE,polypropylene and polypropylene. Although bonding pairs may be chosenfrom the same type, this is not strictly necessary. Certainthermoplastic materials may bond to other such materials not of the sametype.

In another aspect of the invention, there is provided a method offorming a reinforced composite structural member, comprising:

-   -   (i) providing a composite mixture comprising a fibrous material        and a resin;    -   (ii) providing a length of a reinforcing member having at least        one physical characteristic for promoting bonding of said        reinforcing member with said composite mixture;    -   (i) embedding said reinforcing member into said composite        mixture prior to forming said composite structural member.

These and other aspects of the invention will become apparent throughthe illustrative figures and accompanying description provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

In the figures which illustrate example embodiments of the presentinvention:

FIG. 1 is a schematic block diagram of an exemplary processing line forprocessing a composite structural member.

FIG. 2 a is a detailed perspective view of an extrusion apparatus forpracticing the method in accordance with an exemplary embodiment of theinvention.

FIG. 2 b is the extrusion apparatus of FIG. 2 a showing an extrudedsegment of a reinforced composite structural member made in accordancewith an exemplary embodiment of the invention.

FIG. 2 c is a cross-sectional view of the extrusion apparatus of FIGS. 2a and 2 b showing paths for introducing reinforcing members.

FIG. 2 d is a detail of a portion of the extrusion apparatus of FIG. 2c.

FIG. 3 a is a cross-sectional view of the reinforced compositestructural member formed by the extrusion apparatus of FIGS. 2 a to 2 d.

FIG. 3 b is a cross-sectional view of another embodiment of a reinforcedcomposite structural member which may be formed in a substantiallysimilar extrusion apparatus.

DETAILED DESCRIPTION

Referring to FIG. 1, a portion of a processing line 100 for making anextruded product is shown. In this illustrative example, the processingline 100 includes an extruder 110 having a mouth 112 for receiving rawmaterials. The raw materials may be provided, for example, in apelletized or granular form suitable for storage and transportation.Machines located upstream from the extruder 110 which may form suchpelletized or granular raw materials are not shown, but will be familiarto those skilled in the art. Such upstream machines possibly may belocated at a completely different location, such as at a supplier'spremises.

Attached to an end of the extruder 110 is an extrusion apparatus 115. Anextrusion screw 210 (see FIG. 2 c) is provided within the extruder 110to apply suitable pressure on a composite mixture 111 formed from theraw materials therein.

The raw materials fed into mouth 112 may comprise, for example, anysuitable combination of a resin (or resins) and natural fibers (e.g.wood fiber materials). In an embodiment, a suitable ratio for a mixtureof HDPE to wood fiber material may be in the range of approximately50:50 by weight, to 35:65 by weight.

In operation, with the application of an appropriate amount of heat,pressure and agitation within the extruder 110, a composite mixture 111may be formed which has a suitable viscosity for extrusion through theextrusion apparatus 115. For example, for the mixture of HDPE and woodfiber described above, a suitable pressure is preferably in the order of2000 PSI+400 PSI, and a suitable melting temperature is preferably inthe order of between 150°-190° C. Various other ranges of pressure andtemperature may be used for different combinations of resins and naturalfiber materials.

FIG. 1 shows an extruded composite structural member 118 emerging fromthe extrusion apparatus 115. The extruded composite structural member118 may then undergo further processing. For example, the processingline 100 may further include a calibration/cooling machine 120 whichreceives the extruded composite structural member 118 from the extrusionapparatus 115. The calibration/cooling machine 120 may be used, forexample, to maintain the form of the extruded composite structuralmember 118 as the structural member 118 cools down and solidifies. Oncecooled and solidified, the extruded composite structural member 118 mayemerge from the calibration/cooling machine 120 and be pulled by apuller 122. The puller 122 may be provided with belts 124, 126 mountedon rollers which grip the composite structural member 118 from oppositesides. The extruded composite structural member 118 may then emerge fromthe puller 122 and continue on to a finishing and cutting machine (notshown) further down the processing line 100.

Referring to FIG. 2 a, shown is a perspective view of the extrusionapparatus 115 of FIG. 1. As shown, the extrusion apparatus 115 includesa first opening 132 a for receiving, along a path A, a first reinforcingmember 130 a therein. Shown in a hidden view is a second opening 132 blocated on an opposite side of the extrusion apparatus 115. The secondopening 132 b receives, along a path B, a second reinforcing member 130b therein. In the discussion below, the description of the opening 132 aand reinforcing member 130 a should be understood to apply equally toopening 132 b and reinforcing member 130 b, in a corresponding manner.

In an embodiment, the reinforcing member 130 a may be in the form of aflexible strip or tape. The reinforcing member 130 a may be providedwith a plurality of flow-through apertures 133 along the length of thereinforcing member 130 a. In FIG. 2, the flow-through apertures 133 areexaggerated in size for the purposes of illustration. As will beexplained in detail below, these flow-through apertures 133 are adaptedto allow the composite mixture 111 to flow and to solidify therein. Thiswill help to secure the reinforcing member 132 a within the extrudedcomposite structural member 118. It will be understood that, generally,the plurality of flow-through apertures 133 increases the area of thebondable outer surface of the reinforcing member 130 a (in comparison toa reinforcing member of a substantially similar shape and size nothaving said flow-through apertures 133). Also, the flow-throughapertures 133 may provide a “peg-in-hole” anchoring effect, to securethe reinforcing member in the composite structural member a lengthwisedirection.

The flow-through apertures 133 may be provided at regular or randomintervals, and in a variety of shapes, sizes, and patterns. Theflow-through apertures 133 should be sufficiently large to permit thecomposite mixture 111 to flow through into them, but should not be sonumerous, or placed so close together as to render the reinforcingmember 130 a ineffective for bearing a significant tensile load. Thepossibility of nails or screws being driven through the reinforcingmember 130 a should be taken into account in determining the pattern andsize of the flow-through apertures 133.

Suitable materials for the reinforcing member 130 a may include, forexample, carbon composites, steel, aluminum, and other metal, glass andpolymer based materials. Generally speaking, the material chosen for thereinforcing member 130 a can be selected to provide a desired tensilestrength, but can also accommodate a nail, screw or other fastener thatmay be driven into the reinforced composite structural member 118. Thematerial selected should also provide sufficient tensile strength, evenif flow-through apertures 133 are provided. Furthermore, the materialcan be selected to allow the reinforcing member 130 a to be sufficientlyflexible such that a sufficiently long length of the reinforcing member130 a may be provided on a supply reel (not shown). This will facilitatea sufficiently long, continuous run through the extruder 110 to form theextruded composite structural member 118.

In other embodiments, the reinforcing member may take another form thatcan be accommodated within the profile of the extruded compositestructural member 118. For example, in one such embodiment, thereinforcing member 130 a (FIG. 3 b) may be made of fibers braided intothe form of a cable or tow. Instead of a plurality of flow-throughapertures 133, as shown in FIG. 2 a, the braided cable or tow mayprovide a coarse or uneven outer surface.

It will be understood that such a coarse or uneven outer surface willprovide an increased bondable outer surface on said reinforcing member130 a, in comparison to a reinforcing member of a substantially similarshape and size having a substantially smooth outer surface. Furthermore,such a coarse or uneven outer surface will provide greater frictionalforce between the reinforcing member 130 a and the composite mixture111. The cable or tow also provides a greater cross-sectional area forbearing tensile strength.

Still referring to FIG. 2 a, the extrusion apparatus 115 includes anextrusion outlet 117 suitably shaped to form a desired cross-sectionalprofile of the extruded composite structural member 118. For example, inorder to form a number of voids or channels within the profile of theextruded composite structural member 118, a plurality of channel shapingelements 134 a-134 d may be suitably positioned within the extrusionoutlet 117. The channel shaping elements 134 a-134 d may be suspended atthe mouth of outlet 117 by suitably placed braces or webs (not shown)further within the extrusion outlet 117. Preferably, such braces or websshould have a minimal profile, in the direction of flow of the compositemixture 111, so as to minimize any disruption of flow of the compositemixture 111 into extrusion outlet 117.

Now referring to FIG. 2 b, shown is another view of the extrusionapparatus 115 of FIG. 2 a. As shown in FIG. 2 b, a segment of theextruded composite structural member 118 has emerged from the extrusionoutlet 117. Channels 206 a-206 d have been formed by the channel shapingelements 134 a-134 d, respectively. Furthermore, the reinforcing members130 a and 130 b have passed through the extrusion outlet 117 to becomeembedded within the extruded composite structural member 118. Thegeneral direction of flow of the emerging extruded composite structuralmember 118 is indicated by arrow C.

Referring to FIG. 2 c, the extrusion apparatus 115 of FIGS. 2 a and 2 b,and a segment of the extruded composite structural member 118, are shownin a cross-sectional view. As shown, the first reinforcing member 130 afollows a path through opening 132 a into extrusion apparatus 115 andthen in between the channel shaping element 134 a and an extrusionapparatus wall 131 a. Similarly, reinforcing member 130 b follows a paththrough opening 132 b into extrusion apparatus 115, and then in betweenthe channel shaping element 134 d and extrusion apparatus wall 131 b.

Still referring to FIG. 2 c, an extrusion screw 210 provides thenecessary pressure on composite mixture 111 to extrude the mixture 111through the extrusion outlet 117. Within the extrusion apparatus 115,the composite mixture 111 should have a suitable viscosity, andsufficient momentum in the general direction of arrow C, such that thereinforcing members 130 a and 130 b are pulled into and through theextrusion apparatus 115.

In an embodiment, the openings 132 a, 132 b of the extrusion apparatus115 may lead into suitably configured guide channels 212 a, 212 b whichmay guide the reinforcing members 130 a, 130 b into the extrusionapparatus 115, near the extrusion outlet 117, for bonding to thecomposite mixture 111. As shown in FIG. 2 c, the guide channel 212 a isappropriately sized and shaped to allow reinforcing member 130 a to passthrough the extrusion apparatus 115 and be aligned for accurateplacement within the extruded composite member 118. Similarly, guidechannel 212 b is appropriately sized and positioned to allow reinforcingmember 130 b to pass through the extrusion apparatus 115 and be alignedfor accurate placement within the extruded composite member 118. Thesize, shape and length of the guide channels 212 a, 212 b will bedetermined by the outer dimensions of the reinforcing member 130 a, 130b and also by the intended placement location in the profile of theextruded composite member 118.

Now referring to FIG. 2 d, and referring back to FIG. 2 c, in anembodiment, the guide channel 212 b may be provided with a lining 213.The lining may provide guide channel 212 b with different properties.For example, the lining 213 may provide a degree of thermal regulation,allowing the reinforcing member 130 b to be regulated substantiallyindependently of the composite mixture 111. As another example, thelining 213 may provide a sufficiently smooth and hard surface whichprovides a sufficiently smooth entry for reinforcing members 130 a, 130b which may have a coarse or uneven outer surface.

In an embodiment, a suitable temperature gauge 214 may be employed tomonitor the temperature of the guide channel 212 b for more accurateprocess control, although care should be taken in unobtrusively placingthe gauge 214 so as not to hinder movement of the reinforcing member 130b.

If desired, a heating element 215 may be provided along the guidechannel 212 b in order to preheat the surface of the reinforcing member130 b prior to its exit from the guide channel 212 b.

There should not be any back-flow of the composite mixture 111 intoguide channel 212 b, especially if the exit of the guide channel 212 bis suitably sized and shaped for the reinforcing member 130 b. Also, themovement of composite mixture 111 in the general direction of arrow Cshould minimize any such back-flow problems.

Still referring to FIG. 2 d, as shown, the reinforcing member 130 b maybe guided into the opening 132 b by a pair of opposing rollers 220 a and220 b. The rollers 220 a, 220 b may be made of a suitably strong andheat resistant material, such as tungsten carbide or ceramic, forexample. The direction of rotation of each roller 220 a and 220 b isindicated by arrow D and arrow E, respectively. The rollers 220 a and220 b may be initially used in a driving manner to assist in threadingthe reinforcing member 130 b into the guide channel 212 b and throughthe extrusion apparatus 115. Once the extrusion process is under way,however, the rollers 220 a, 220 b may then become suitably biasedagainst such rotation to regulate tension on the reinforcing member 130b as it is pulled into the extrusion apparatus 113. (In anotherembodiment, the two functions, driving and tensioning, may be performedby two separate sets of rollers.) Depending on the type of the materialused, and the material's flexibility, appropriate tensioning of thereinforcing member fiber 103 b may help to impart a desired strengthcharacteristic in the finished product.

The rate of introduction of reinforcing member 130 b into the extrusionapparatus 115 will be determined by the rate of formation of theextruded composite structural member 118 through the extrusion apparatus115. Consequently, the rate of introduction of the reinforcing member130 b should be carefully matched with the rate of formation of theextruded composite structural member 118 in order to obtainsubstantially uniform product characteristics along substantially theentire length formed in a processing run.

In the vicinity of the exit of guide channel 212 b, the compositemixture 111 flows into a funnel shaped entrance to gap 225. Sufficientpressure is present in this region such that the composite mixture 111flows around and makes substantial contact with the reinforcing member130 b as it emerges from the guide channel 212 b. Any flow-throughapertures 133 provided on the reinforcing member 130 b are filled by thecomposite mixture 111.

In another embodiment, the reinforcing member 130 b may be coated ortreated with a resin, selected to be compatible with the resin used inthe composite mixture 111, such that a solid bond may be formed betweenthe reinforcing member 130 b and the composite mixture 111.Advantageously, preparation of the composite mixture 111 and preparationof the reinforcing member 130 b for bonding can proceed substantiallyindependently, up to the point that reinforcing member 130 b is extrudedtogether with composite mixture 111 through the extrusion apparatus 115.

Referring to FIGS. 3 a and 3 b, shown are cross-sectional views of anextruded composite structural member 118 formed by the method andapparatus shown and described above. The reinforcing members 130 a and130 b are placed within the composite structural member 118 and bondedto the surrounding composite material to provide assistance in bearingtensile forces under a load A or a load B, as the case may be.

As shown in FIG. 3 a, in the case of a reinforcing member 130 a, 130 bprovided with flow through apertures, such flow-through apertures 133may be filled in by the composite mixture. This may help to keep toreinforcing member 130 a, 130 b firmly in position within the compositematrix.

As shown in FIG. 3 b, in an alternative embodiment, the reinforcingmembers 130 a, 130 b may comprise braided cables or tows having a coarseouter surface. As explained earlier, such a coarse surface may providean effectively greater surface area for bonding to the surroundingcomposite mixture 111, and may also provide a greater frictional forcebetween the reinforcing members 130 a, 130 b and the surrounding matrixof the extruded composite structural member 118. Also, the braided cableor tow shape provides a greater cross-sectional area for bearing tensilestresses.

Still referring to FIGS. 3 a and 3 b, if the extruded compositestructural member 118 is bearing load A on side 300 b, between two fixedsupports (not shown) supporting side 300 a, then reinforcing memberfiber 130 a will be in tension. Similarly, if load B is applied to side300 a, say between two fixed supports (not shown) supporting side 300 b,then reinforcing member fiber 130 b will be in tension. By having thesymmetrical arrangements shown, it will be understood that the extrudedcomposite structural member 118 provides virtually the same structuralloading characteristics regardless of which side, 300 a or 300 b, isbearing a load.

While certain illustrative embodiments of the present invention has beenshown and described, various modifications will be apparent to thoseskilled in the art. For example, while an extrusion process has beendescribed, it will be appreciated that various aspects of this inventionmay be adapted to pultrusion and injection molding techniques. As well,while the illustrative extruded composite structural member is shown anddescribed as having a plurality of channels, it will be understood thatthe teachings of the present invention are equally applicable tostrengthening an extruded composite structural member with just onechannel, or without such channels (i.e. a member having a solidcross-section). Also, the shape of the internal channels may vary. Whilethe extruded composite structural member is shown as having a generallyrectangular shape, it will be understood that various other shapes mayalso be used. As well, while the reinforcing member is shown as beingembedded substantially along the entire length of a composite structuralmember, it will be appreciated that only a portion of a length of acomposite structural member may be reinforced in this manner, ifappropriate to do so.

Therefore, the invention is defined in the following claims.

1. A reinforced composite structural member, comprising: a solidifiedcomposite mixture of a fibrous material and a resin; a reinforcingmember embedded therein, said reinforcing member having at least onephysical characteristic for promoting bonding of said reinforcing memberwith said mixture of a fibrous material and a resin.
 2. The reinforcedcomposite structural member of claim 1, wherein said compositestructural member is formed by extrusion.
 3. The reinforced compositestructural member of claim 1, wherein said physical characteristiccomprises an increased bondable outer surface in comparison to areinforcing member of a substantially similar shape and size having asubstantially smooth outer surface.
 4. The reinforced compositestructural member recited in claim 1, wherein said physicalcharacteristic comprises a plurality of flow-through apertures.
 5. Thereinforced composite structural member recited in claim 4, wherein saidreinforcing member is in the form of a strip, and said flow-throughapertures are provided along the entire length of said strip.
 6. Thereinforced composite structural member recited in claim 1, wherein saidphysical characteristic comprises a resin compatibly bondable with saidresin in said composite mixture.
 7. The reinforced composite structuralmember recited in claim 1, wherein said physical characteristiccomprises a coarse outer surface.
 8. The reinforced composite structuralmember recited in claim 7, wherein said reinforcing member is a braidedcable having said coarse outer surface.
 9. The reinforced compositestructural member recited in claim 8, wherein said reinforcing memberincludes a resin compatibly bondable with said resin in said compositemixture.
 10. The reinforced composite structural member recited in claim1, wherein said fibrous material is a natural fiber.
 11. The reinforcedcomposite structural member recited in claim 1, wherein said fibrousmaterial is wood fiber.
 12. The reinforced composite structural memberrecited in claim 1, wherein said reinforcing member includes ananchoring feature to secure said reinforcing member in said compositestructural member in a lengthwise direction.
 13. A method of forming areinforced composite structural member, comprising: (i) providing acomposite mixture comprising a fibrous material and a resin; (ii)providing a length of a reinforcing member having at least one physicalcharacteristic for promoting bonding of said reinforcing member withsaid composite mixture; (iii) embedding said reinforcing member intosaid composite mixture prior to forming said composite structuralmember.
 14. The method recited in claim 13, wherein (iii) is performedduring extrusion of said composite mixture.
 15. The method recited inclaim 13, wherein said physical characteristic comprises an increasedbondable outer surface in comparison to a reinforcing member of asubstantially similar shape and size having a substantially smooth outersurface.
 16. The method recited in claim 13, further comprising, priorto (iii), applying sufficient heat, pressure and agitation to saidcomposite mixture to bring said resin to its melting point, and saidcomposite mixture of said natural fiber and said resin to a flowing,extrudable state.
 17. The method recited in claim 16, wherein saidcharacteristic comprises providing on said reinforcing member a resincompatibly bondable with said resin in said composite mixture.
 18. Themethod recited in claim 13, further comprising thermally regulating saidreinforcing member strip independently of said composite mixture, up tothe point of said embedding in (iii).
 19. The method recited in claim13, wherein in (ii) said providing a length of a reinforcing member withat least one physical characteristic for increasing the area of thebondable outer surface of said reinforcing member comprises providing aplurality of flow-through apertures on said reinforcing member.
 20. Themethod recited in claim 19, further comprising providing on saidreinforcing member a resin compatibly bondable with said resin in saidcomposite mixture.
 21. The method recited in claim 13, wherein in (ii)said providing a length of a reinforcing member with at least onephysical characteristic for increasing the area of the bondable outersurface of said reinforcing member comprises providing a coarse outersurface.
 22. The method recited in claim 21, further comprisingproviding on said reinforcing member a resin compatibly bondable withsaid resin in said composite mixture.
 23. The method recited in claim22, further comprising heating the outer surface of said reinforcingmember as said reinforcing member is embedded in (iii).
 24. The methodrecited in claim 13, wherein said reinforcing member is provided in aflexible format, allowing a sufficiently long length of said reinforcingmember to be supplied on a reel.
 25. The method recited in claim 14,further comprising providing guiding said reinforcing member into anextrusion apparatus and immediately adjacent to an extrusion apparatusoutlet for proper alignment within said reinforced composite structuralmember.
 26. The method recited in claim 13, wherein said fibrousmaterial is a natural fiber.
 27. The method recited in claim 13, whereinsaid fibrous material is wood fiber.